Configurable cooling assembly and cooling method

Abstract

The present invention provides a configurable cooling assembly and cooling method. An assembly of thermally conductive cooling blocks is configured to be placed against a composite skin between a heating blanket used to heat cure a composite repair patch and a structure formed by heat-sensitive materials. The cooling block assembly conducts heat away from the skin to prevent overheating of the heat-sensitive materials.

Description

Technical Field

[0001] The present disclosure relates generally to systems and methods for cooling structures, and more particularly to configurable cooling block arrays for directing heat away from a structure. Background Art

[0002] Sometimes it is necessary to protect heat sensitive structures from overheating. For example, to perform in-situ repairs of composite structures such as composite aircraft skins, heating blankets are used to thermally cure composite repair patches placed over the area of ​​the skin that needs repair. In some cases, the skin repair area is located close to heat sensitive materials (HSMs) such as underlying titanium or aluminum stiffeners.

[0003] Depending on the difficulty of the application, shot bags, cold air streams, and / or fans acting as heat sinks may be used to cool the skin between the edge of the heating blanket and the HSM to prevent the HSM from overheating. However, in other applications, the distance between the edge of the heating blanket and the HSM may be quite small (e.g., on the order of a few inches), thereby limiting the effectiveness of the cooling fan. The difficult task of preventing the HSM from overheating is made more difficult by complex geometries and difficult to reach repair areas. Summary of the invention

[0004] The present disclosure relates generally to cooling of structures to prevent overheating of HSMs, and more particularly to a reconfigurable cooling assembly for conducting heat away from the HSM in the vicinity of a bond repair.

[0005] According to one aspect, an apparatus for cooling a structure is provided, the apparatus comprising an assembly of a configurable thermally conductive cooling block. The cooling block is configured to be placed against a surface of the structure and fit within a space of a predetermined volume adjacent the structure.

[0006] According to another aspect, an apparatus for preventing overheating of heat-sensitive material adjacent to a repair patch being heat cured on a composite skin by a heat source is provided. The apparatus comprises an assembly of thermally conductive cooling blocks configured to be placed against the composite skin for conducting heat away from the composite skin between the heat-sensitive material and the heat source.

[0007] According to yet another aspect, a method of controlling the temperature of a heat-sensitive material located adjacent to a repair patch heat-cured on a composite skin using a heating blanket is provided, the method comprising: configuring an assembly of thermally conductive cooling blocks to fit within a space between the heating blanket and the heat-sensitive material; and mounting the assembly of thermally conductive cooling blocks against the skin within the space.

[0008] One advantage of the cooling assembly is that it is simple, non-powered, can be installed in a compact space, and can be easily configured to fit unusual or complex geometries of structures required for cooling. Another advantage of the cooling assembly is that it can be reused and reconfigured to obtain different heat sink shapes and cooling levels required in different applications. Yet another advantage of the cooling assembly is that it avoids the need to interrupt thermal curing of the composite patch when there is a risk of overheating of the adjacent HSM.

[0009] The features, functions, and advantages can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The novel features believed to be of the exemplary embodiments are set forth in the appended claims. However, the exemplary embodiments, together with the preferred modes of use, further objects and advantages of the exemplary embodiments, will be best understood by reference to the following detailed description of exemplary embodiments of the present disclosure when read in conjunction with the accompanying drawings, in which:

[0011] Figure 1 is an illustration of a schematic cross-sectional view of a composite skin in which a HSM is located adjacent an area of ​​the skin requiring repair;

[0012] Figure 2 is similar to Figure 1 , but showing the installation of a configurable cooling block assembly;

[0013] Figure 3 is along Figure 2 An illustration of a cross-sectional view taken along line 3-3 in FIG. 1 , wherein one of the cooling blocks in the cross-section is removed to reveal an internal through hole;

[0014] Figure 4 is an illustration of a perspective view of one of the cooling blocks forming part of a configurable cooling block assembly;

[0015] Figure 5 yes Figure 2 and Figure 3 An illustration of a fragmentary side view of a row of cooling blocks shown in , wherein the blocks are cut away in section to reveal a continuous air passage through the row of cooling blocks;

[0016] Figure 6 is an illustration of an end view of a plurality of cooling blocks, the figure showing one form of interconnection between the cooling blocks;

[0017] Figure 7 is an illustration of an end view of a plurality of cooling blocks, this figure showing another form of interconnection between the cooling blocks;

[0018] Figure 8 is an illustration of an end view of a plurality of cooling blocks, this figure showing yet another form of interconnection between the cooling blocks;

[0019] Fig. 9 is an illustration of an end view of a plurality of cooling blocks held against an underlying composite skin by gravity;

[0020] Fig.10 yes Fig. 9 Marked as " Fig.10 ” area;

[0021] Fig.11 is an illustration of a partial perspective view showing the use of cooling blocks in the process of repairing a composite skin that is bent in two dimensions;

[0022] Fig.12 are illustrations of end views of two of the cooling blocks supported on an underlying contoured skin surface;

[0023] Fig.13 yes Fig.12 Marked as " Fig.13 ” area;

[0024] Fig.14 is an illustration of a flow chart of a method for cooling a structure including a HSM;

[0025] Fig.15 It is a diagram of a flow chart of aircraft production and maintenance methods;

[0026] Fig.16 is an illustration of a block diagram of an aircraft. DETAILED DESCRIPTION

[0027] Figure 1 A composite laminate structure such as a composite aircraft skin 20 is shown having an area 22 (hereinafter referred to as a "repair area") that requires in-situ repair or rework to correct an out-of-specification condition such as impact damage. Although not shown in the drawings, the repair is performed using a cured or uncured composite laminate patch that is bonded to the skin 20 using an adhesive. A curing assembly (not shown) including a heating blanket 28, which is typically composed of a fiber-reinforced thermoset or thermoplastic laminate, is used to thermally cure the adhesive and / or the repair patch. The curing assembly may also include a vacuum bag (not shown) that is used to hold the repair patch in place during the curing process.

[0028] The repair area 22 is positioned adjacent to a heat sensitive material (HSM) 24, which in the illustrated embodiment comprises a structural stiffener 24a having a cap 26 bonded or otherwise secured to the surface 20a of the skin 20. A minimum amount of space 34 exists between the edge 28a of the heating blanket 28 and the HSM 24. The stiffener 24a may comprise an HSM 24 (such as, but not limited to, inlaid titanium or aluminum) that is affected when heated above a certain temperature. The temperature at which the HSM 24 is affected is below the cure temperature (in the case of a thermoset patch) or the consolidation temperature (in the case of a thermoplastic patch) of the repair patch. For convenience, in the remainder of the description, "cure temperature" refers to the cure temperature of a composite laminate repair patch formed from a thermosetting polymer resin, a thermoplastic polymer resin, a hybrid material system containing both thermosetting and thermoplastic materials, and an adhesive used to bond such a patch to an underlying structure such as the skin 20. While titanium inserts are affected when exposed to temperatures exceeding 200° F., the heating blanket 28 can generate temperatures well in excess of 200° F. for thermosetting repair patches, such as 300° F. to 350° F. During the repair patch heat curing process, the thermal energy generated by the heating blanket 28 is transferred to the stiffener 24 a by both radiation 32 and conduction 30 through the skin 20 , thereby raising the temperature of the HSM 24 .

[0029] Now refer to Figures 2 to 4 , an assembly 36 of thermally conductive cooling blocks 38 arranged in a three-dimensional array (hereinafter "cooling block assembly") is placed against the surface 20a of the skin 20. As will be discussed in more detail below, the cooling block assembly 36 is used to control the temperature of the HSM 24. The cooling block assembly 36 is configured to fit into a space 34 ( 20a ) between the edge of the heating blanket 28 and the cap 26 of the stiffener 24a. Figure 1 ) within. In the illustrated embodiment, the cooling block assembly 36 includes a three-dimensional array of individual cooling blocks 38 arranged in five layers on a lower support 39 that holds the cooling block assembly 36 against the skin surface 20a. In the accompanying drawings, the support 39 includes a flat plate that is driven upward by a jack or similar force applicator to force the assembly 36 of cooling blocks 38 against the skin surface 20a. However, a variety of other devices such as straps, scaffolding, etc. that support the cooling blocks 38 and force them against the skin surface 20a are feasible. Although Figure 2 Five layers 44 of cooling block 38 are shown in FIG, but more than five layers 44 or as few as one layer 44 may be suitable depending on the application. Figure 2 and Figure 3 The layers 44 of the middle cooling block 38 are shown as being staggered to increase the exposed surface area of ​​the assembly, but they may be vertically aligned to form rows and columns.

[0030] The cooling block assembly 36 controls the temperature of the HSM 24 by acting as a heat sink, conducting a portion 46 of the heat from the skin away from the HSM 24, so that only the remaining portion 48 of the heat conducted through the skin 20 reaches the HSM 24. The amount of heat conducted away from the skin 20 by the cooling block assembly 36 will depend on several factors, including, but not limited to, the number of cooling blocks 38 in contact with the surface 20a of the skin 20, the thermal conductivity of the cooling blocks 38, the total mass of the cooling blocks 38, and the surface area of ​​the cooling blocks 38 exposed to the surrounding environment. In addition to reducing the heat conducted to the HSM 24 through the skin 20, the cooling block assembly 36 also absorbs heat radiated 32 by the heating blanket 28, which would otherwise affect the HSM 24.

[0031] As in Figure 4 As best seen in FIG. 1 , each cooling block 38 is in the shape of a cube having equal dimensions of height H, width W, and length L. However, in other embodiments, these dimensions may not be equal. For example, each cooling block 38 may be elongated, wherein its length L is much greater than its height H or its width W. Moreover, although the cooling blocks 38 shown are shaped with flat surfaces that maximize surface contact between the cooling blocks 38, other shapes are possible. For example, the cooling blocks 38 may be rectangular, cylindrical, or pyramidal in shape (to name just a few possible shapes). The surfaces of the cooling blocks 38 should have a smooth surface (with minimal porosity) in order to maximize heat transfer between the interfaces of adjacent blocks 38. The cooling blocks 38 are composed of a material that has a relatively high thermal conductivity and is easily machined (for example, but not limited to, copper or aluminum or alloys of these two or other thermally conductive materials). The thermal conductivity of the cooling blocks 38 should be sufficient to minimize the residual heat conduction 48 reaching the HSM 24.

[0032] Depending on the application, some of the cooling blocks 38 may have one or more through holes 40 therein, each of which has an appropriate diameter. In the illustrated embodiment, the top or first layer 44 of the cooling blocks 38 that contacts the skin 20 does not have any through holes 40, while the cooling blocks 38 in the second layer 44 and the third layer 44 each have a single through hole 40, and the cooling blocks 38 in the fourth layer 44 and the fifth layer 44 each have four through holes 40. The through holes 40 increase the exposed surface area of ​​the cooling blocks 38 and therefore increase the amount of heat that radiates away from the cooling blocks 38 to the surrounding environment. The space 34 ( Figure 1 ) In relatively small applications, it may be desirable to use cooling blocks 38 closest to the skin 20 that do not have through holes 40 because the lack of through holes 40 increases the thermal mass of those cooling blocks 38, thereby allowing the cooling blocks to conduct heat away from the skin 20 more quickly.

[0033] Now also refer to Figure 5In one embodiment, the cooling block 38 is arranged such that the through holes 40 are aligned to form a continuous air channel 42 through the cooling block assembly 36, thereby allowing passive convection cooling. Alternatively, active cooling can be achieved by forcing air 50 through the channel 42 using a fan 52 or other forced air source. The air 52 flowing through the channel 42 draws heat away from the cooling block assembly 36, thereby enhancing the ability of the cooling block assembly to cool the skin 20 and reducing the increase in the temperature of the HSM 24 caused by the heating blanket 28.

[0034] Depending on the application, it may be necessary or desirable to releasably connect the cooling blocks 38 together via releasable mechanical interconnection means, adhesive means, or other means. Figure 6 One arrangement is shown for mechanically interconnecting the cooling blocks 38 using interlocking wedges 54 and slide slots 56 that allow the cooling blocks 38 to be slidably assembled with one another. Figure 7 Another arrangement is shown in which each cooling block 38 includes one or more embedded magnets 58. The magnets 58 in adjacent cooling blocks 38 align with each other and attract each other, thereby magnetically holding the cooling blocks 38 in the assembly 36 together. Figure 8 Yet another arrangement is shown in which a pin or releasable snap-fit ​​fastener 60 (such as, but not limited to, a ball and socket connection) is used to interconnect the cooling blocks 38. In some applications, the fastener 60 may comprise a simple pin. A variety of other techniques may be used to hold the cooling blocks 38 together into the assembly 36 (including, but not limited to, thermally conductive adhesives).

[0035] Fig. 9 and Fig.10 Another embodiment is shown in which an assembly 36 of cooling blocks 38 (only three of which are shown in the drawings) is held against the composite skin 20 by gravity. To locate and position the layers of cooling blocks 38 relative to each other, the bottom 38a of each cooling block 38 is provided with one or more raised locating balls 64 which are received in corresponding indexing recesses 62 in the top surface 38b of the cooling block 38 below.

[0036] The cooling block assembly 36 can be used to conduct heat away from the curved or contoured composite skin 20. For example, referring to Figures 11 to 13 , one or more layers 44 of cooling blocks 38 are arranged on top of the composite skin 20, positioned within the space 34 between the edge 28a of the heating blanket 28 and the underlying stiffener 24a formed by the HSM 24. The composite skin 20 curves in two dimensions, and the cooling block assembly 36 generally follows the contour of the skin 20. With particular reference to Fig.12 and Fig.13The bottom 38a of the cooling block 38 is substantially flat, and thus a small gap 68 ( Fig.13 ).

[0037] Depending on the application, a thermally conductive liquid gasket 70 may be used to fill the gap 68 to prevent or minimize the amount of heat loss transferred from the skin 20 to the cooling block 38. Depending on the curvature of the skin surface 20a, a relatively small pie-shaped gap 66 may be formed between the walls of adjacent cooling blocks 38. The gap 66 may be used to allow convective air flow through the cooling block assembly 36, optionally by a fan (eg, a fan) that forces air through the gap 66. Figure 5 Alternatively, gap 66 may be filled with a liquid shim 70. In some applications, each of gaps 66, 68 may be filled with a thermally conductive metal shim (not shown).

[0038] Fig.14 A method for cooling a structure such as a skin 20 including a heat sensitive material 24 is shown. Beginning at step 72, a plurality of cooling blocks 38 are fabricated, and optionally at step 74, at least one through hole 40 is formed in at least some of the cooling blocks 38. At step 76, an assembly 36 of cooling blocks 38 is configured to fit within a space 34 between a heating blanket 28 and the heat sensitive material 34. Optionally, the cooling blocks 38 are interconnected. At step 78, the assembly 36 of cooling blocks 38 is mounted against a composite skin 20 within the space 34. At step 80, heat is transferred away from the composite skin 20 to the outside environment using the assembly 36 of cooling blocks 38. Optionally, as shown at step 82, active cooling may be employed, such as using a fan 52 to force air 50 over / through the cooling blocks 38.

[0039] Embodiments of the present disclosure may find use in a variety of potential applications, particularly in the transportation industry including, for example, aerospace, marine, automotive applications, and other applications where heat-sensitive materials must be protected from overheating. Fig.15 as well as Fig.16 , which can be found in Fig.15 Aircraft manufacturing and maintenance method 84 and the like Fig.16 Examples of the present disclosure are described in the context of an aircraft 86 as shown. Aircraft applications of embodiments of the present disclosure may include, for example, but not limited to, fuel and hydraulic systems using tubes containing pressurized fluids. During pre-production, an exemplary method 84 may include specification and design 88 of an aircraft 86 and material procurement 90. During production, component and subassembly manufacturing 92 and system integration 94 of the aircraft 86 are performed. Thereafter, the aircraft 86 may be certified and delivered 96 for entry into service 98. While in service with a customer, the aircraft 86 is scheduled for a routine maintenance check 100 (which may also include modification, reconfiguration, refurbishment, etc.).

[0040] The various processes of exemplary method 84 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0041] like Fig.16 As shown, an aircraft 86 produced by the exemplary method 84 may include an airframe 102 having a plurality of systems 104 and an interior 106. The airframe 102 may include heat-sensitive materials that must be protected from overheating during, for example, thermal curing of a composite repair. Embodiments of the high-level systems 104 include one or more of a propulsion system 108, an electrical system 110, a hydraulic system 112, and an environmental system 114. Any number of other systems may be included. Although an aerospace embodiment is shown, the principles of the present invention may be particularly applicable to other industries such as the military industry and the automotive industry.

[0042] The apparatus and methods embodied herein may be employed during any one or more stages of the manufacturing and service method 84. For example, components or subassemblies corresponding to the production process 92 may be assembled or manufactured in a manner similar to the production of components or subassemblies for the aircraft 86 while in service. Furthermore, one or more aspects of the apparatus embodiments, method embodiments, or a combination of these aspects may be utilized during the production stages 92 and 94, such as to significantly speed up the assembly of the aircraft 86 or reduce the cost of the aircraft 86. Similarly, one or more aspects of the apparatus, method, or a combination of these aspects may be utilized, such as, but not limited to, when the aircraft 86 is in service (e.g., during the maintenance overhaul 100).

[0043] Furthermore, the present disclosure includes implementations according to the following clauses:

[0044] Clause 1: An apparatus for cooling a structure, the apparatus comprising: an assembly of configurable thermally conductive cooling blocks configured to be placed against a surface of a structure and to fit within a space of a predetermined volume adjacent the structure.

[0045] Clause 2: The apparatus of clause 1, wherein the assembly comprises a plurality of cooling blocks arranged in a three-dimensional array.

[0046] Clause 3: The apparatus of clause 1, wherein each cooling block is formed from one of copper and aluminum.

[0047] Clause 4: The apparatus of clause 1, wherein the cooling blocks include releasable connections that couple the cooling blocks together and allow the cooling blocks to be reconfigured.

[0048] Clause 5: The apparatus of clause 1, wherein at least some of the cooling blocks include at least one through hole that allows air to pass therethrough.

[0049] Clause 6: The apparatus of clause 1, wherein the assembly comprises a plurality of cooling blocks arranged in a row and having through holes therein, the through holes being aligned to form an air passage through the row of cooling blocks.

[0050] Clause 7: The apparatus of clause 6, comprising a fan configured to force air through the air passage.

[0051] Clause 8: An apparatus for preventing overheating of heat-sensitive material adjacent a repair patch being heat cured on a composite skin by a heat source, the apparatus comprising: an assembly of thermally conductive cooling blocks configured to be placed against the composite skin for conducting heat away from the composite skin between the heat-sensitive material and the heat source.

[0052] Clause 9: The apparatus of clause 8, wherein the cooling block is formed from one of copper and aluminum.

[0053] Clause 10: The apparatus of clause 8, wherein each cooling block is cube-shaped.

[0054] Clause 11: The apparatus of clause 8, wherein the cooling blocks are arranged in a three-dimensional array.

[0055] Clause 12: The apparatus of clause 8, wherein the cooling blocks include interconnecting means that couple the cooling blocks together.

[0056] Clause 13: The apparatus of clause 12, wherein the interconnect is releasable to allow reconfiguration of the shape of the components of the cooling block.

[0057] Clause 14: The apparatus of clause 12, wherein the interconnection means comprises one of: a slot and a wedge formed in each cooling block; a pin between cooling blocks; a snap-fit ​​fastener; a magnet; and a conductive adhesive between cooling blocks.

[0058] Clause 15: The apparatus of clause 8, wherein at least some of the cooling blocks include at least one through hole therein that allows air to pass therethrough.

[0059] Clause 16: A method of controlling the temperature of a heat-sensitive material positioned adjacent to a repair patch heat-cured on a composite skin using a heating blanket, comprising: configuring an assembly of thermally conductive cooling blocks to fit within a space between the heating blanket and the heat-sensitive material; and mounting the assembly of thermally conductive cooling blocks against the skin within the space.

[0060] Clause 17: The method of clause 16, wherein the step of configuring comprises: placing the cooling blocks in a row and column arrangement; and maintaining the cooling blocks in this arrangement.

[0061] Clause 18: The method of clause 16, wherein the step of configuring includes forming through holes in at least some of the cooling blocks to allow air to pass therethrough.

[0062] Clause 19: The method of clause 18, comprising directing heat away from the cooling block by forcing air through the through holes.

[0063] Clause 20: The method according to clause 16, further comprising:

[0064] Disassemble the cooling block assembly; and

[0065] Reassemble the cooling block in another configuration.

[0066] As used herein, the phrase "at least one of..." when used with a series of items means that different combinations of one or more of the items in the series may be used and only one of the individual items in the series may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, item A, item A and item B, or item B. This embodiment may also include item A, item B and item C, or item B and item C. Items may be special objects, events, or categories. In other words, any combination of items from the series and at least one of several items may be used but all items in the series are not required.

[0067] Various exemplary embodiments have been described for purposes of illustration or description and are not intended to be exhaustive or limited to the embodiments disclosed. Some variations and modifications will be apparent to those of ordinary skill in the art. Moreover, different exemplary embodiments may provide different functionality relative to other exemplary embodiments. The selected embodiments are selected and described in order to best explain the principles of the embodiments, the practical application, and to enable those of ordinary skill in the art to understand the present disclosure for various embodiments with various modifications suitable for the specific application contemplated.

Claims

1. A method of controlling the temperature of a heat sensitive material positioned adjacent to a repair patch being heat cured on a composite skin using a heating blanket, the method comprising: configuring an assembly of a thermally conductive cooling block to fit within the space between the heating blanket and the heat-sensitive material; and The assembly of thermally conductive cooling blocks is mounted against the skin within the space, forming a heat sink that conducts a portion of the heat from the composite skin away from the heat sensitive material.

2. The method according to claim 1, wherein: The steps of the configuration include: placing the cooling blocks in a row and column arrangement; and The cooling block is maintained in the arrangement.

3. The method according to claim 1, wherein: The step of configuring includes forming through holes in at least some of the cooling blocks to allow air to pass therethrough.

4. The method of claim 3, comprising directing heat away from the cooling block by forcing air through the through holes. 5 . The method of claim 3 , further comprising arranging the cooling block such that the through holes are aligned to form a continuous air passage through components of the cooling block.

6. The method of claim 3 further comprising arranging the cooling blocks into a plurality of layers, wherein the cooling blocks in the layer closest to the composite skin have the fewest number of through holes, and the cooling blocks in the layer farthest from the composite skin have the greatest number of through holes.

7. The method according to claim 1, further comprising: disassembling the components of the cooling block; and The cooling block is reassembled in another configuration.

8. The method according to claim 1, wherein: The cooling block is formed of one of copper and aluminum.

9. The method according to claim 1, wherein: The cooling block includes interconnects coupling the cooling block together, and wherein the interconnects are releasable to allow reconfiguration of the shape of the components of the cooling block.

10. The method according to claim 1, wherein: The interconnection means comprises one of the following: slots and wedges formed in each cooling block; cooling pins between blocks; Snap-fit ​​fasteners; magnets; and Conductive adhesive between cooling blocks.

11. The method of claim 1, further comprising arranging the cooling block to absorb heat radiated by the heating blanket.

12. The method according to claim 1, wherein: Each of the cooling blocks includes one or more embedded magnets, wherein the magnets in adjacent cooling blocks align with and attract each other, thereby magnetically holding the cooling blocks in the assembly together.

13. The method according to claim 1, wherein: Each of the cooling blocks includes one or more raised positioning balls on a bottom surface and one or more indexing recesses on a top surface, wherein the indexing recesses are configured to receive positioning balls on another cooling block to position the layers of the cooling blocks relative to each other.

14. A method for controlling the temperature of a heat-sensitive material, the method comprising: configuring an assembly of a thermally conductive cooling block to fit within a space of a predetermined volume between a heat source and the heat-sensitive material, wherein the heat source and the heat-sensitive material are connected by a physical structure; and The assembly of thermally conductive cooling blocks is mounted against the physical structure within the space, forming a heat sink that conducts a portion of the heat from the physical structure away from the heat-sensitive material.

15. The method according to claim 14, wherein: The step of configuring includes forming through holes in at least some of the cooling blocks to allow air to pass therethrough.

16. The method of claim 15, comprising directing heat away from the cooling block by forcing air through the through holes.

17. The method of claim 15, further comprising arranging the cooling blocks into a plurality of layers, wherein the cooling blocks in the layer closest to the physical structure have the least number of through holes, and the cooling blocks in the layer farthest from the physical structure have the greatest number of through holes.

18. The method according to claim 14, wherein: The cooling block includes interconnects coupling the cooling block together, and wherein the interconnects are releasable to allow reconfiguration of the shape of the components of the cooling block.

19. The method of claim 14, further comprising arranging the components of the cooling block to absorb heat radiated by the heat source.

20. A method of controlling the temperature of a heat sensitive material positioned adjacent a repair patch being heat cured on a composite skin using a heating blanket, the method comprising: an assembly of thermally conductive cooling blocks configured to fit within the space between the heating blanket and the heat-sensitive material, wherein certain of the cooling blocks include at least one through hole that allows air to pass therethrough, and wherein the assembly of cooling blocks is constructed to include: at least one cooling block layer without through holes; at least one cooling block layer having a through hole; at least one cooling block layer having more than one through hole; and The assembly of thermally conductive cooling blocks is mounted against the skin within the space, forming a heat sink that conducts a portion of the heat from the composite skin away from the heat sensitive material, wherein the cooling block layer without through holes is closest to the composite skin.

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